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This paper is about the mechanical design and analysis of a yokeless and segmented armature axial flux permanent-magnet (PM) synchronous machine, which consists of two external rotors and an inner stator. Although this new electrical machine has many advantages such as high torque density, shorter axial length, and high efficiency, its mechanical construction is yet challenging. This is mostly due to the high axial force between the stator and the two rotors, which can be further increased by the inevitable manufacturing and assembly tolerances. Based on the determined geometric dimensions of the electromagnetically relevant components, a reliable mechanical construction is developed in this paper. Subsequently, stress, deformation, thermal, and modal analyses are performed based on finite-element method (FEM). Finally, the first prototype is successfully manufactured and measured. It can be concluded that the proposed construction is reliable and the measured data match well with the results of the electromagnetic analysis. [ABSTRACT FROM AUTHOR]

The design rules of winding configurations and stator-pole/rotor-tooth (SP/RT) number combinations of doubly-fed flux-switching permanent magnet (DF-FSPM) machines are investigated in this paper based on coil electromotive force (EMF) vectors. The relationships between the components of stator and rotor coil-EMF vector diagrams are unveiled at first, including the numbers of stator and rotor phases, and the numbers of stator and rotor spokes. Then, the SP/RT number combinations are derived considering feasible stator/rotor phase number combinations and different winding configurations. The SP/RT number combinations are optimized considering the winding factors, magnetic field harmonics, unbalanced magnetic forces and machine diameter. It is shown that both of the stator and rotor pitch factors increase when the SP and RT numbers get closer. Furthermore, the influence of winding configurations and SP/RT number combinations on electromagnetic performances of DF-FSPM machines are analyzed by finite-element method. Finally, the analysis results are validated by experiment. [ABSTRACT FROM AUTHOR]

This paper addresses a simple and computationally efficient dynamic model for brushless permanent magnet (PM) motors under PM demagnetization faults. The impact of stator slots and spatial disposition of the windings are taken into account to improve the accuracy of a lumped-parameter $abc$ model. This model is suitable for tracking the dynamic behavior of fault components, as it can be accompanied by any control scheme and/or be used for model-based fault detection schemes. In addition, parameters of this model can be automatically tuned by an optimization process in the offline phase of the healthy machine. Finite-element simulations are carried out for proving the effectiveness of the proposed model. Verification is done in both time and frequency domains for four PM motors with different rotor and stator configurations. The simulation results are experimentally verified. [ABSTRACT FROM AUTHOR]

The transverse flux permanent-magnet (PM) linear machine has attracted much attention in high-performance direct-drive applications because of its high torque density and efficiency. However, due to its inherent large open-circuit flux leakage, the prominent cogging force makes it difficult to obtain a high accuracy in position and speed control, which restricts its potential for precision industrial processing applications. To overcome this problem, a novel transverse flux linear machine is proposed in this paper. The key is by creatively combining a consequent-pole mover design and a stator-segment-interlacing configuration in such a way that a parallel and complementary transverse magnetic circuit is realized for the moving PMs, which can effectively minimize the open-circuit leakage flux and cogging effect. In this paper, the machine structure, operation principle, and theoretical modeling are introduced, with its electromagnetic performance evaluated by using the finite-element method. A prototype is also built for the experimental verification, and relevant test results agree well with the finite-element predications. [ABSTRACT FROM AUTHOR]

Low-speed flux-modulated permanent-magnet (PM) machines do not need to conform to the conventional design rule which requires identical number of pole-pairs in both stator and rotor. In flux-modulated machines, special ferromagnetic segments in the airgap are used to modulate the magnetic field. In this paper, a general rule to compare different types of electric machines as well as measures to improve the torque density in these machines are presented. In this paper, the energy conversion capacity of different machines with the same physical size and the same operating temperature-rise are compared. An adaptive-order method for modeling the load—temperature-rise relationship is presented to reduce the computing time for this inverse problem. Three power-electronic-driven PM electric machines, which are, namely, a traditional PM machine, a radial-flux-modulated machine (RFMM), and an axial-flux-modulated machine (AFMM), are analyzed and compared based on their temperature distribution and electromagnetic torque density using magnetic field and thermal field computation. Experimental results of an AFMM prototype are used to validate the temperature-rise which is computed using 3-D finite-element method (3-D FEM). [ABSTRACT FROM PUBLISHER]

Fractional-slot concentrated-winding (FSCW) permanent magnet (PM) machines have been widely studied in recent years. This is mainly due to the several advantages, including high power density, high efficiency, short end turns, high fill factor, low cogging torque, good flux-weakening and fault-tolerant performance. However, the key challenges of utilizing FSCW-PM machines are the abundant stator magnetomotive force (MMF) harmonics. In this paper, the multiphase star–delta hybrid connection (SDHC) windings configuration that can eliminate some stator MMF harmonics is systematically studied. First, the general relationship between the number of slots and phases which are appropriate for the SDHC windings configuration is derived. In addition, the particular principle of the MMF harmonics elimination by the SDHC windings configuration is researched. In order to verify the analysis results, four three-phase SDHC FSCW-PM machines with different slot–pole combinations are built and calculated by the finite-element method. Finally, experiments on a prototype three-phase 12-slot ten-pole FSCW-PM machine are carried out for validation. [ABSTRACT FROM AUTHOR]

Analytical calculation methods for all the major components of the synchronous inductance of tooth-coil permanent-magnet synchronous machines are reevaluated in this paper. The inductance estimation is different in the tooth-coil machine compared with the one in the traditional rotating field winding machine. The accuracy of the analytical torque calculation highly depends on the estimated synchronous inductance. Despite powerful finite element method (FEM) tools, an accurate and fast analytical method is required at an early design stage to find an initial machine design structure with the desired performance. The results of the analytical inductance calculation are verified and assessed in terms of accuracy with the FEM simulation results and with the prototype measurement results. [ABSTRACT FROM PUBLISHER]

The fault-tolerant capabilities are compared in this paper for the conventional double-layer switched-flux permanent-magnet machine and its single-layer counterparts, i.e., C-core, E-core, and modular. The comparison includes the interturn short-circuit and irreversible demagnetization faults. A combination of Simulink and finite element models is used in the study. Based on the predictions, it is found that the modular topology produces the lowest short-circuit current and also has the best demagnetization withstand capability while the conventional one produces the highest short-circuit current and has the worst demagnetization withstand capability. The frozen permeability method is employed to separate the flux produced by armature current and magnets, and the results showed that, besides the influence of short-circuit current, the available magnet volume and magnetic circuit configuration play an important role in the demagnetization process. It is also found that removing half of the magnets, such as using C-core, E-core, and modular topologies, generally improves the demagnetization withstand capability and also increases the torque per magnet volume. Measured results are also presented to validate the short-circuit current predictions and magnet demagnetization. [ABSTRACT FROM PUBLISHER]

Axial-flux permanent magnet (AFPM) machines are gaining popularity in low-speed and high torque applications due to their high torque density, high efficiency, and compact structure. In this article, a dual-rotor slotless AFPM (DRSAFPM) machine equipped with equidirectional toroidal winding (EDTW) is proposed and compared with that equipped with conventional single-layer and double-layer concentrated windings (CWs). First, the differences between the DRSAFPM machine with EDTW and that with conventional CWs in coil layout, electromotive force (EMF), and winding magnetomotive force are revealed. Considering the special coil layout of the EDTW, the coil factor and size equations of the DRSAFPM machines with EDTW and conventional CWs are presented. Second, the electromagnetic performance including air-gap field, back-EMF, torque, and efficiency of the DRSAFPM machines with EDTW and conventional CWs are analyzed based on the three-dimensional finite-element method. The simulation results validate the correctness of the coil factor and size equations and indicate the EDTW–DRSAFPM machine has superiority in back-EMF amplitude and torque density. Finally, a prototype of the EDTW–DRSAFPM machine is manufactured and tested, which validates the feasibility of the EDTW–DRSAFPM machine and the correctness of the analysis. [ABSTRACT FROM AUTHOR]

Variable reluctance resolvers (VRRs) have been widely used for rotor position detection in harsh working conditions. However, conventional installation of VRRs inevitably occupies the axial space of machine systems, and may weaken the reliability of rotor position detection encountering shock and vibration. In this article, a novel VRR structure with inner stator is investigated, which is radially integrated inside a permanent magnet synchronous machine (PMSM) to construct compact machine topology. The hybrid machine topology is first discussed, and detailed electromagnetic design is carried out. Improved analytical analysis on air gap flux density distribution and inductance evaluation of the integrated VRR is derived based on modified winding function approach, and testified by finite element analysis. A prototype is manufactured from an existing 2.2 kW PMSM, and experiments are conducted to validate the effectiveness of proposed machine topology. [ABSTRACT FROM AUTHOR]

Permanent magnet synchronous motors (PMSMs) with nonconcentric magnetic poles (NCMP) structure are widely used as high-precision servo motors. The current subdomain method mainly equates the NCMP to a rectangular magnet to make each subdomain boundaries of magnet parallel when calculating the magnet eddy current loss (ECL), which results in a lower accuracy of the calculation. This article divides the NCMP into nonconcentric region and concentric region along the radial direction. The nonconcentric region is further divided along the circumferential direction, and each divided region has a single thickness. Based on the subdomain method, a novel analytical method of magnet ECL in PMSMs with NCMPs is proposed. Moreover, the three-dimensional distribution coefficient of ECL in the NCMP is derived by the equivalent impedance method. The effects of eddy current reaction and stator slotting are taken into account to improve the calculation accuracy. Then, through theoretical derivation, the relationship between the minimum magnet loss and the pole parameters is obtained, which provides a reference for the design of NCMPs. Finally, the loss separation experiment is performed on four prototypes with NCMPs. The experimental results, finite element method results and analytical results are compared to verify the correctness of the model. [ABSTRACT FROM AUTHOR]